Hello everyone My T4 2.4D has started jumping out of 5th Gear Its an 02B Gearbox changed the oild not long ago and fitted the short shift conversion, could it be the engine mounts moving making it jump out or is it somthing internal ? Seems to do it more when i'm towing or the first 10 miles of a trip. thinking of fitting a Golf TDI 5th gear anyway which is longer gear. thanks
Yes twice, i'll have another check tonite but its not loosing any oil, will also draing down and remove the cover to check the 5th Gear. Here's a thread of changing the 5th for a Golf TDI 5th , could it be the selector shown that is at fault. http://www.vwt4forum.co.uk/showthread.php?t=83109
ok cool, just wanted to double check! shortly after doing oil on mine i noticed a slight drip from the drain plug as I hadn't done it up quite enough see. cant see the link, is it the same as this one: http://wiki.the-corrado.net/5th_gear_cog_change.html
5th Gear swap taken from T4 Forum, were i'm a member and this will be my next job. This is how i did my 5th gear swap tutha day & the tools i used to do the job,,first off you will need a mate to help with foot on the brake pedal while in 5th gear for you to undo the main 2 gear bolts & again while you torque them back up the old 5th gear ratio is little gear 34 teeth big gear 44 teeth divide 34 by 44 which gives you a over all ratio = 0.772 the new gear ratio is small gear 32 teeth big gear 47 teeth which gives you a over all ratio of = 0.680 if your end cover is like this then you can do the conversion this is as is when the cover is off & you need to remove the big spring clip to get the syncro out spring marks in red & the locating blocks marked in green,these hold the syncro together syncro housing marked in red undo the two 12 point bolts that hold the selector folk in place bolts marked red unclip the spring & hold the housing whilst holding the 3 syncro blocks & slide the lot off the gear the red section shows where i put the 2 leg puller & the green section show the part of the gear to heat up with a blow touch "Its A Must To Ease The Gears Off" appily tension to the puller then give the gear a good old heating then apply more heat & so on slightly better picture & you must put the gear bolts back in there threads while using the puller or you will damage the shaft threads this is what it looks like once removed & note the red section marking the needle roller bearing,,again this will slide off know probs be careful its breakable,,also note iam getting the small gear warmed up ready for pulling,,again same method appies for pulling this gear as with the big gear this is what i had to do to the puller to get it to fit in between the back of the gear & the gear box housing "Theres Know Other Way I Could Get In" picture shows one leg modded but you will ahve to mod both legs with the angle grinder & a "Slitting Disc" I put the new samll gear in the oven for about 15 mins to get it hot & then hand fitted it then used the bolt to pull it home "Easy" Its the syncro gear that needs heating then pulling home "Not" your new big gear,that can be fitted along with the needle roller first this shows it all together,but i will try to explain the syncro blocks as i call them & the spring clip its riddly but do"able you need to slip them over the spring thats built into the syncro hub then sort of open them whilst fitting the spring clip they will resist thats how they work/hold it all together it sounds harder than it is,,once thats on fit the syncro folk,i got my mate to work the gear lever "Verrrry" slowly sort of going for 5th but not just to aid the selctor folk then once she is in bolt her up & get ya mate to select 5th if the syncro hub goes inwards towards the gear box your cooking on gas,,i got him the go for 5th at least half dozen times till i was happy with how it looked & sounded. i bought one of these sets knowning i did "Not" want to get stuck,i paid 42 for it but it will come in handy for other jobs on the van sorry about the pics "Mobile Phone" note the bit on the left as 6 points & the bit on the right as 12 points folk think torx are torx there not,this kit as 3 different types & your Vw T4 van gear box uses two of them the torque settings are as follows the 2 gear bolts T60 Bit @ 59 ft-lbs Folk arm Selector M8 Bit @ 18 ft-lbs part numbers Small Gear 02D 311 361 Big gear 02D 311 158 195 from Vw & worth every penny i also drained the gear box & refilled with 75W90 semi synthetic 2.5 Lts,,looks like veg oil tonnes better than the black contaminated stuff that came out. right i hope ive got everything sorry if ive missed anything,Oh forgot put it in 5th gear foot on brake to undo & same again when tightening she now sits at 60 mph 2300 rpm 70 mph hair over 3000 rpm 85 mph 3500 rpm iam running 205/55/16 tyres which will improve this but all in all well worth it,she will trundle along with traffic at 30 mph in 5th just
Same as the 02a/j, always a ***** getting either the hub or small gear off, especially when the small gear is on the large side and you can't get a pulled in there.
Martyn havn't done mine yet, but would you know why its jumping out of 5th at the moment while driving ? cheers
100k of easy driving, but jumping out of 5th at the moment so i am trying to find out why at the moment.
Took the T4 out for a drive today and lost all drive in 5th gear , its been jumping out of 5th gear and making so i'm in search for a TDI 5th Gear to replace the damaged gears. new gear ratio required is small gear 32 teeth big gear 47 teeth which gives you a over all ratio of = 0.680
Found this link for the parts , but looks like i'll get them new from the main dealers if i can't get some from an old box. http://www.idparts.com/catalog/product_info.php?cPath=99&products_id=520 either that or i'm driving to the Pod next week in 4th all the way with the trailer on. here's a good "how to do 5th gear " thread. http://www.myturbodiesel.com/1000q/multi/5th-gear-swap-VW.htm
O2A ratios: _________1st___2nd___3rd___4th___5th___R&P___Notes ATA====3.778 =2.105 =1.345=0.971=0.795=3.684==Corrado G60 AYL====3.778=2.118=1.429=1.029=0.837=3.684==Corrado G60 CAW====3.77=2.118=1.458=1.034=0.838=3.647==Corrado G60 CDM====3.300=1.944=1.308=1.034=0.838=3.647==Corrado VR6 AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V AYK====3.778=2.118=1.429=1.029=0.837=3.684= Passat 16v CES====3.778=2.118=1.429=1.029=0.837=3.684== Passat? CHA====3.778=2.118=1.360=0.917=0.717=3.944==VR6 Canada CGY====3.778=2.118=1.458=1.029=0.837=3.684== Passat? CNL====3.778=2.118=1.458=1.029=0.837=3.684==VR6 Passat? CCM====3.300=1.944=1.308=1.034=0.838=3.389==VR6 Passat, Jetta, Golf CTN====3.778=2.118=1.360=1.029=0.755=3.157==Jetta/Golf/Passat TDI Beware these have 02J style output flanges. I've heard that people need to order 02J diffes for them. I'll know soon as I have one for my TDI Corrado and I plan to install a peloquin. DQY====3.778=2.118=1.360=1.029=0.755=3.389==Jetta/Golf TDI ASD====3.300=1.944==1.308==1.09==0.717==3.16==TDI I've heard of a few being bought in the USA but I believe its a euro MK3 TDI tranny CHN==== Golf CHU==== 4.24 R&P and its from a 2L Passat CRU====3.300=1.944=1.308=0.971=0.755=4.24===B4 Passat ABA CDA====3.30==1.944=1.308=1.029=.838=3.68===MK3 ABF (euro 2L 16V) O2C trannys (SYNCRO): CBC,CHD=3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro CDN AYR ====3.778=2.118=1.345=0.971=0.756=3.944== Passat Syncro CDH====3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro Ok here are the Part numbers for the different 5th gears For the .755 gearing you'll need: 02a311361Q is $142.77 and 02a311158E is $226.05 For the .717 gearing you'll need: 02a311361M is $142.77 and 02a311158R is $226.05 Some 02J tranny codes provided by a kind Vortexer that looked them up on his bentley 1.8T trannys coded: EBQ, EMT, EGX, FBW: _1st___2nd___3rd___4th___5th___R&P_ 3.300-1.944-1.308-1.029-0.837-3.938 TDI trannys coded: DQY, EBJ, EGR: _1st___2nd___3rd___4th___5th___R&P_ 3.788-2.118-1.360-0.971-0.756-3.389 2.0 trannys coded: DZQ, EBP, EGT, EKG, EKH, EMS, EZK, FBV: _1st___2nd___3rd___4th___5th___R&P_ 3.778-2.118-1.360-1.029-0.837-4.235 VR6 trannys coded: DZC, EHC, EGF, EWW, FBY, FCF _1st___2nd___3rd___4th___5th___R&P_ 3.625-2.071-1.474-1.038-0.844-3.389 1.8T trannys coded: EHA _1st___2nd___3rd___4th___5th___R&P_ 3.300-1.944-1.308-1.029-0.837-3.65 The EHA gearing is confirmed by Bentley:
Brookster. Is there Any T4 owners you know have done this? Maybe their old 0.755 gears are for sale for me?
Looks like the 5th gear end is a little cooked, the cause of the jumping. Due to the way the box is designed if the oil level gets low it starves the 5th gear end, and basically burns it out. It jams up and starts to wear the gears out due to excessive contact. If you've lost teeth then it'll need a strip down and clean out to check for other damage incase it's gone throughout the box.
Thanks Martin The lack of oil was due to the garage who did the clutch, i will be going to see them this week. I've cleaned out the box and everything esle looks ok. also looks like i have found the 02A 311 361 Gear. and i will have to order the 02D 311 158 Gear from the dealers.